Oil Degassing Rig manual (pdf 398KB)
Contents
1. Contents General Albany Rotary Gear Pump WEG electric motor Edwards RV5 vacuum pump Manufacturers literature Issue 1 MECHATE SS aaa Page 2 of 16 NNN NAAA 10 10 11 11 11 11 12 12 12 12 12 13 13 13 14 14 14 6 TECHNICAL SPECIFICATIONS 7 ENVIRONMENT SPECIFICATIONS Contents Issue 1 MECHATE SS aaa Page 3 of 16 15 16 1 DOCUMENTATION RECORDS Documentation Update Details Approval Project version 1a developed and issued 22 06 11 JH for internal review First formal issue to customer 22 06 11 Section 1 Issue 1 Page 4 of 16 MECHATE SS aa 2 INTRODUCTION 2 1 Purpose This manual provides installation and operation instructions for the Oil Degassing Rig This manual and all accompanying documentation must be read before operating the vacuum system Important safety information is highlighted as WARNING and CAUTION instructions you must obey these instructions The use of WARNINGS and CAUTIONS are defined below 2 2 General safety WARNING Warnings are given where failure to observe the instruction could result in injury or death to persons CAUTION Cautions are given where failure to observe the instruction could damage to the equipment associated equipment or process Refer to the accompanying manufacturers instruction manuals for the technical data on individual components 2 3 Unpack and inspect Remove all packing material CAUTION Rem2. container of oil to be transferred 6 Open the Vacuum Spoil valve located immediately above the System Air Admit valve This will maintain a pressure of approx 55 65 mb during filling to control excessive foaming of the degassing oil 7 Depress the Circulation pump push button switch on the control panel to start the oil circulation pump Push button will illuminate Section 4 to 5 Issue 1 Page 9 of 16 MECHATE SS aaa 10 11 12 13 Select the Heater with its rotary switch on the control panel to initiate the heating of the oil Note The heaters will not turn on Rotary switch illuminated until the oil level rises to actuate lift the lower float If the blue Reset push button also illuminates depress to extinguish The temperature controller displays the set point temperature in green lower display value and the actual temperature in red upper display value The annunciator will sound when the chamber is at approximately the 28 0I level to warn the operator The mute push button will illuminate To mute the alarm press the Mute push button The indicator will extinguish Close the Fast fill valve and disconnect the flexible pipe from the push in fitting Leave the Vacuum Spoil valve open for a further 35 45 mins experience and oil type will determine allowing the oil to heat circulate and degass without excessive foaming Close the Vacuum Spoil valve and ob
3. requirements are Thornbury available from MechaTech Systems Ltd Bristol BS35 3UR 44 0 1454 414723 enquiries mechatechsystems co uk www mechatechsystems co uk Section 4 to 5 Issue 1 Page 13 of 16 MECHATECH SYSTEMS ME E 5 2 2 Albany Rotary Gear Pump WEG electric motor For the Rotary gear pump and motor refer to the individual manufacturer s literature for spares 5 2 3 Edwards RV5 vacuum pump For the vacuum pump refer to the individual manufacturer s literature for spares 5 2 4 Manufacturers literature Manufacturer s literatures for all major components have been included Section 4 to 5 Issue 1 Page 14 of 16 MECHATECS aa 6 TECHNICAL SPECIFICATIONS Table 2 Technical Specifications FUNCTION MODEL PERFORMANCE Edwards Vacuum Pump RV5 Refer to manufacturers manual Albany Circulation Pump AP4 RV Refer to manufacturers manual Electrical 230V 50Hz 1 ph 3 KW Dimensions w xh x I Overall 600 x 1750 x 1020 mm Dimensions h x dia Chamber internal 706 x 300 mm Weight Empty Overall 180 Kg Noise Overall lt 80 dB Section 6 Issue 1 Page 15 of 16 MECHATECH SYSTEMS ME E 7 ENVIRONMENT SPECIFICATIONS e Temperature Operation 12 to 40 C e Temperature Storage 30 to 70 C e Humidity Operation 50 to 90 RH non condensing e Humidity Storage 5 to 95 RH non condensing e Protection IP22 Electrical control panel Section 7 Issue 1 MECHATESS ma Pa
4. the left hand and smaller hexagon at the base of the filter assembly and drain oil into a suitable container To aid the draining of the filter housing unscrew the hexagon headed plug in the top of the filter cap 5 Unscrew the filter cap this may be quite stiff and withdraw filter element from the top of the filter housing Do not attempt to unscrew the filter body 6 Fit new filter element and replace cap 7 Refit the two hexagon plugs using new sealing washers and return the filter slide to its original position 8 Re tighten securing screw and open the Reservoir ISO valve Section 4 to 5 Issue 1 Page 11 of 16 MECHATE SS aa 5 MAINTENANCE WARNING Ensure that the electrical supply is isolated before starting any maintenance work Ensure all power is disconnected and the oil has cooled sufficiently Operate the manual air admit valve located on the top of the reservoir Planned Maintenance When performing the following operations refer to the components own working instructions for details on how to carry out the specified items all of the necessary working instructions are supplied with this manual 5 1 1 Daily Maintenance e Inspect inner and outer glass surfaces for scratches or other surface damage e Inspect check the Albany pump for normal operation as follows 1 Noise 2 Vibration 3 Bearing temperature 4 Product leaks 5 Seals for leakage e Check oil level in vacuum pump 5 1 2 6 monthly ma
5. a a SYSTEMS MMM TECHNICAL VACUUM SOLUTIONS UK MANUFACTURERS OF THE LYOSCIENCE LS RANGE OF FREEZE DRYERS amp BESPOKE HIGH VACUUM SYSTEMS VACUUM PUMPS SPARES SERVICE Mobile Oil Degassing Rig INSTALLATION AND OPERATION MANUAL Please Read This Document before Operating the Machinery MechaTech Systems Ltd Unit 9 Brunel Way Thornbury Industrial Estate Thornbury Bristol BS35 3UR Tel 44 0 1454 414723 Email enquiries mechatechsystems co uk www mechatechsystems co uk Registered in England and Wales No 6469333 VAT Reg no 928 7530 93 Jms b oo Alles sogo Y MechaTech Systems 2013 All rights reserved CONTENTS 1 DOCUMENTATION RECORDS 2 INTRODUCTION 2 1 Purpose 2 2 General safety 2 3 Unpack and inspect 2 4 Installation and Commission 2 4 1 2 4 2 2 4 3 2 4 4 2 4 5 Lifting and Handling Instructions Initial setup Electrical requirements Mechanical requirements Additional Documents to be supplied 3 OVERVIEW 3 1 General Description 4 OPERATION 4 1 Filling the reservoir 4 2 Filling component 4 3 Setting the temperature set point 4 4 Reset filter replacement indicator 4 5 Reset over temperature trip 4 6 Shut Down 4 7 Oil filter change 5 MAINTENANCE Planned Maintenance 5 1 1 5 1 2 5 1 3 5 1 4 Daily Maintenance 6 monthly maintenance Preventative Maintenance Calibration 5 2 Recommended Spares 5 2 1 5 2 2 5 2 3 5 2 4
6. details WARNING Failure to refit all panels prior to connecting to mains power may result in injury or death to the operator 2 4 4 Mechanical requirements Pump Exhaust NW25 flange Tool evac reservoir fill 8mm push fit Fast reservoir fill top of reservoir 12mm push fit 2 4 5 Additional Documents to be supplied Electrical Circuit Diagrams ref 8666 P amp ID ref 10129 Declaration of Conformity ref 31W082 Albany rotary Gear Pump maintenance instructions WATLOW Temperature controller EZ Zone PM Express user s manual ref 0600 0065 0000 Rev D WATLOW Temperature limit series L users manual Edwards Active Gauge Controller ref D395 90 000 Issue E Active Pirani Gauge D026 01 880 Issue B Please read these manuals before putting the unit into operation Section 2 Issue 1 Page 7 of 16 MECHATECH systems ME E 3 OVERVIEW 3 1 General Description The Oil Degassing Unit is for the purpose of degassing filtering insert media The system consists of a mobile trolley mounted glass oil reservoir with aluminium base and top plates fluid and vacuum pumps and a control panel with vacuum fluid and temperature instrumentation During the degassing cycle the fluid pump continually circulates oil through an in line filter heater block and spreader plate back into the reservoir During this cycle the chamber is evacuated using the onboard vacuum pump Temperature and pressure are monitored via gauges mounted on the con
7. ge 16 of 16
8. intenance e RV5 full service e Albany pump inspections as follows 1 Check all pump bolting and connections are tight and free from corrosion 2 Check lubrication schedule 3 Check alignment 4 Check all ancillary equipment is in working order e Calibrate gauges 5 1 3 Preventative Maintenance e Albany pump lubricated bearings should be charged at 2000 hours and re packed with new grease every 4000 hours Section 4 to 5 Issue 1 Page 12 of 16 MECHATE SS aaa 5 1 4 Calibration It is recommended that all vacuum gauging and sensors fitted to this unit be returned to MTS or a relevant competent body for service and calibration at least every 12 months The time interval between services must to be reviewed by the customer during the units operating life 5 2 Recommended Spares 5 2 1 General Table 1 Recommended Spare Parts List Description Part No Manufacturer Filter element 12 micron UE219AS08Z PAL Chamber seals x2 TR300 QVF Process Systems Ltd Mist filter element A22304198 Edwards Vacuum Ultragrade 19 oil H11025013 Edwards High Vacuum Albany pump Gear Pump AP4 RV relief valve 240V 1ph 0 37KW 50Hz Albany Pumps Cartridge heater 5 8 Diameter x 6 long 240V 500W 39 Teflon leads and seal Watlow Gauge head DO2601000 Edwards Vacuum Spares and service MECHATECH SYSTEMS ME MechaTech Systems Ltd Unit 9 Brunel Way All spare parts and servicing
9. k procedure above and select 4 Section 4 to 5 Issue 1 Page 10 of 16 MECHATE SS aaa 4 4 Reset filter replacement indicator To reset the filter blocked indicator after the filter has been replaced depress the button in the end of the electrical connection at bottom of filter housing The red flag showing inside of the button will then disappear The filter indicator on the front control panel should then extinguish 4 5 Reset over temperature trip Press Overtemp reset illuminated indicator switch to reset output once temperature is back in safe region The factory set over temperature set point is 100 C 4 6 Shut Down Deselect the Heater with its rotary switch light will extinguish Press the circulation pump stop push button light will extinguish Press the Vacuum pump stop button light will extinguish Switch off the mains isolator ae ee ae 4 7 Oil filter change WARNING When the filter needs to be changed ensure that the oil in the system is at ambient temperature WARNING Ensure that the electrical supply is isolated 1 The oil filter housing is mounted onto a sliding platform When the filter is to be changed slacken the M8securing screw in the slide housing beneath the trolley base and pull out the filter on its sliding platform as far as it will go 2 Close the Reservoir ISO valve beneath the chamber base plate yellow T handle 4 Unscrew filter drain bolt
10. ove all packing material before operating system If the equipment is damaged notify your supplier and the carrier in writing within three days Section 2 Issue 1 Page 5 of 16 MECHATE SS aa 2 4 Installation and Commission 2 4 1 Lifting and Handling Instructions Casters 9 are fitted allowing the unit to be pushed to location 2 4 2 Initial setup Locate the Oil Degassing Rig in the required position ensuring that the floor is adequate to support the equipment and that due consideration is given to a Air flow for ventilation b Adequate space for maintenance Il Once in final position the Vacuum Degassing Rig can be connected to the power supply CAUTION Exhaust gases must be ducted away from the surrounding atmosphere and suitably disposed CAUTION Do not obstruct any vacuum pump exhaust port refer to manufacturer s manual before operation Section 2 Issue 1 Page 6 of 16 MECHATECH SYSTEMS ME E 2 4 3 Electrical requirements CAUTION The unit is factory configured for 230volts 13 amps single phase supply Check that your voltage supply is compatible If you operate the unit on the wrong voltage you will damage it Voltage 230Vac Frequency 50 60Hz Loading power consumption 3 KW Earthing Class 1 supply earth required Fusing 13A Ensure that all framework panels are refitted before connecting to any services Refer to Electrical Circuit Diagrams ref 8666 for supply connection
11. serve the oil level to ensure Foaming is not excessive or has stopped Continue to degass oil for required time or until required vacuum level has been achieved NOTE For the heater to work there are three conditions that must be met 1 The circulation pump must be running 2 The over temp device must be reset 3 There must be sufficient oil in the reservoir measured by the lower level switch 4 2 Filling component 1 Using the two 8 0 Dia push in fittings connect the Oil to RST and Oil from RST to the appropriate points on the RST Component To evacuate the RST Component Open the Oil flow from RST valve And evacuate until the desired vacuum level is reached To fill the RST Component with oil Move the RST Bypass valve from Bypass to Fill When the RST Component filling is complete Close the Oil flow from RST valve and Move the RST Bypass valve back to Bypass 4 3 Setting the temperature set point The control set point value is displayed in the lower display window while in the auto mode of operation To unlock the controller press and hold both the Up arrow and the Down arrow keys until LOC is displayed then select 1 with Down arrow key To change the set point press either the Up arrow Down arrow keys to increment or decrement the set point value Any change will automatically be entered after three seconds To again lock the controller follow the unloc
12. trol panel During the Tool fill cycle the operator evacuates the Tool Then he diverts the flow of oil to fill the Tool Oil returning from the Tool is passed back into the reservoir An Indicator on the control panel when illuminated warns the operator of the need to replace the filter Section 3 Issue 1 Page 8 of 16 MECHATE SS aaa 4 OPERATION WARNING The glass chamber surface temperature can reach greater than 70 c Do not touch without wearing appropriate PPE WARNING It is recommended that protective gloves or suitable PPE should be worn when operating the Degassing Rig 4 1 Filling the reservoir 1 Connect the unit to the mains supply and switch on the mains isolator located below the control panel 2 Ensure The System Air Admit valve located on the top of the reservoir is closed The RST Bypass valve is in the Bypass position The Oil Flow Reservoir fill valve is closed The Fast Fill valve is closed positioned on top of the chamber Yellow handle See section 4 2 The Vacuum Isolation valve is open handle vertical 3 Depress the Vacuum pump push button switch on the control panel to start the vacuum pump button will illuminate 4 Monitor the vacuum level Allow the rig to evacuate until the analogue gauge on the top of the unit reads 30 inHG 5 Attach a 12 0mm dia nylon pipe to the fast fill valve Immerse the other end of the pipe into the
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